Powder metal rocker arm

Abstract

A powder metal rocker arm is provided. The rocker arm may be connected to a cylinder head of an engine to assist in transferring motion between engine components. The rocker arm includes a pivot aperture formed therein to facilitate pivoting of the rocker arm with respect to the cylinder head. The rocker arm is formed of a metal alloy powder. The metal alloy powder is compacted to form an intermediate member. Secondary features, such as apertures and other weight reducing features may be formed in the intermediate member. The intermediate member is then sintered to form the rocker arm.

1 . A rocker arm comprising:
 a first end;   a second end opposite said first end;   a pivot aperture capable of receiving a pivot pin;   wherein said rocker arm is comprised of a metal alloy powder that is compacted and sintered to form said rocker arm; and   wherein at least one aperture is formed in said rocker arm prior to said rocker arm being sintered.   
     
     
         2 . The rocker arm of  claim 1  further comprising a recessed portion formed in said rocker arm. 
     
     
         3 . The rocker arm of  claim 2  wherein said recessed portion is formed in said rocker arm prior to said rocker arm being sintered. 
     
     
         4 . The rocker arm of  claim 1  wherein said pivot aperture is formed in said rocker arm prior to said rocker arm being sintered. 
     
     
         5 . The rocker arm of  claim 1  wherein said first end is connected to a rod coupled to a camshaft. 
     
     
         6 . The rocker arm of  claim 1  further comprising a touch pad formed in said second end of said rocker arm. 
     
     
         7 . The rocker arm of  claim 6  wherein said touch pad is formed in said rocker arm prior to said rocker arm being sintered. 
     
     
         8 . A rocker arm assembly comprising:
 a rocker arm support member;   a pivot pin connected to said rocker arm support member   a first rocker arm pivotally connected to said pivot pin;   wherein said first rocker arm is comprised of a metal alloy powder that is compacted and sintered to form said first rocker arm; and   wherein at least one secondary feature is formed in said first rocker arm prior to said first rocker arm being sintered.   
     
     
         9 . The rocker arm assembly of  claim 8  wherein said secondary feature includes an aperture formed in said first rocker arm. 
     
     
         10 . The rocker arm assembly of  claim 8  further comprising a second rocker arm connected to said rocker arm support member. 
     
     
         11 . The rocker arm assembly of  claim 8  wherein said rocker arm support member is connected to a cylinder block of an engine. 
     
     
         12 . The rocker arm assembly of  claim 11  wherein a first end of said first rocker arm is connected to a rod. 
     
     
         13 . The rocker arm assembly of  claim 12  wherein a second end of said first rocker arm is connect to a valve stem. 
     
     
         14 . The rocker arm assembly of  claim 12  wherein said first end of said first rocker arm includes an aperture configured to receive said rod. 
     
     
         15 . A method of forming a rocker arm comprising:
 compacting a metal alloy powder into a die to form an intermediate rocker arm member;   forming a secondary feature in said intermediate rocker arm member; and   sintering said intermediate rocker arm member to form a rocker arm.   
     
     
         16 . The method of  claim 15  wherein said secondary feature includes a weight reducing feature formed in said intermediate rocker arm member. 
     
     
         17 . The method of  claim 15  wherein said secondary feature includes an aperture formed in said intermediate rocker arm member. 
     
     
         18 . The method of  claim 17  wherein said aperture is a pivot aperture formed in said intermediate rocker arm member. 
     
     
         19 . The method of  claim 15  further comprising the step of mixing said alloy powder prior to compacting said alloy powder. 
     
     
         20 . The method of  claim 15  further comprising the step of forming a touch pad in an end of said intermediate rocker member.